Dental prosthetic assemblies and coupling systems

ABSTRACT

A dental prosthetic assembly includes a semi-flexible reinforcement bar and a polymer and glass outer layer chemically luted to the semi-reinforcement bar outside of the reinforcement bar. The semi-flexible reinforcement bar forms an interior of the dental prosthetic assembly and at least a portion of the polymer and glass outer layer forms teeth of the dental prosthetic assembly. A coupling system of a dental prosthetic assembly includes pins disposed in openings extending into the dental prosthetic assembly and implant abutments configured to be coupled with a mouth of a patient. The implant anchors have horizontal holes configured to receive the pins. The pins secure the dental prosthetic assembly to the implant abutments by moving into the dental prosthetic assembly through the openings and into the holes of the implant abutments.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/785,536, which was filed on 17-Oct.-2017, and which claims priorityto U.S. Provisional Application No. 62/412,913, filed on 26-Oct.-2016.The entire disclosures of these applications are incorporated herein byreference.

FIELD

Embodiments of the subject matter described herein relate to implantsupported dental prosthetics.

BACKGROUND

Dental prosthetics, such as fixed dentures, can be used to replace allor some missing teeth in a mouth. Currently known dentures arefabricated from materials that are unable to withstand extended use dueto fracturing and disassembly, creating inconvenience and hardship forthe patient. For example, some dentures are fabricated from a titaniumbar having manufactured teeth bodies (shapes of manufactured teeth areprocessed on the titanium bar). These materials do not form any chemicalbond between the bar, processed acrylic on the bar, and the manufacturedteeth. Therefore as a result, the processed acrylic and teeth bodies canseparate and break from the titanium bar easily, resulting in a poorchoice for a fixed denture.

Other fixed dentures may be milled from solid zirconia. While thesetypes of dentures also suffer from the drawbacks associated with thetitanium-acrylic based dentures, the solid zirconia material is a veryhard and heavy material and can create significant discomfort forpatients while chewing food and general mastication. The solid zirconiadentures have little to no flexibility and therefore can fractureeasily.

Currently known dentures may be fixed inside a patients' mouth usingscrews that extend through the dentures and into facial implants of thepatient. The screws tend to be very small and difficult to remove.During servicing of the dentures, attempted removal of these screws canbe difficult and risk damage to the screws and the prosthesis. This canresult in extensive additional dental work required to remove thedamaged or broken screws.

BRIEF DESCRIPTION

In one embodiment, a dental prosthetic assembly includes a semi-flexiblereinforcement bar and a polymer/glass outer layer that is chemicallyluted to the semi-flexible reinforcement bar using a dual cure bondingsystem. The semi-flexible reinforcement bar forms an interior of thedental prosthetic assembly and the polymer/glass portion of the outerlayer forms teeth of the dental prosthetic assembly.

In one embodiment, a coupling system of a dental prosthetic assemblyincludes pins that move in and out in openings that extend into thedental prosthetic assembly and implant custom abutments that areconfigured to be coupled with a mouth of a patient. The implantabutments have horizontal holes configured to receive the pins. The pinssecure the dental prosthetic assembly to the implant abutments by movingthe pins into the dental prosthetic assembly through the openings andinto the horizontal holes of the implant abutments.

In one embodiment, a method includes obtaining a semi-flexiblereinforcement bar, obtaining a polymer/glass outer layer, chemicallybonding the reinforcement bar with the polymer/glass outer layer, andmilling artificial teeth into the polymer-based outer layer to form adental prosthetic assembly. The reinforcement bar forms an interior ofthe dental prosthetic assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter described herein will be better understood fromreading the following description of non-limiting embodiments, withreference to the attached drawings, wherein below:

FIG. 1 illustrates a dental prosthetic assembly according to oneembodiment of the inventive subject matter described herein;

FIG. 2 illustrates another view of the dental prosthetic assembly shownin FIG. 1 according to one embodiment;

FIG. 3 illustrates another view of the dental prosthetic assembly shownin FIG. 1 according to one embodiment;

FIG. 4 illustrates another view of the dental prosthetic assembly shownin FIG. 1 according to one embodiment;

FIG. 5 illustrates another view of the dental prosthetic assembly shownin FIG. 1 according to one embodiment;

FIG. 6 illustrates another view of the dental prosthetic assembly shownin FIG. 1 according to one embodiment;

FIG. 7 illustrates another view of the dental prosthetic assembly shownin FIG. 1 according to one embodiment;

FIG. 8 illustrates implant abutments of a coupling system according toone embodiment;

FIG. 9 illustrates implant abutments of the coupling system according toone embodiment; and

FIG. 10 illustrates a flowchart of one embodiment of a method forproviding a dental prosthetic assembly.

DETAILED DESCRIPTION

Embodiments of the inventive subject matter described herein relate todental prosthetics, such as dentures, formed from a new combination ofmaterials that remedies many problems associated with currently knowndental prosthetics. Other embodiments described herein relate to dentalprosthetic coupling systems that allow persons to easily remove theprosthetics inside patients' mouths and re-attach the prosthetics insidethe patients' mouths, without significant risk to damaging the patientsor prosthetics.

FIGS. 1 through 3 illustrate views of a top side of a dental prostheticassembly 100 according to one embodiment of the inventive subject matterdescribed herein. FIGS. 4 through 7 illustrate views of a bottom side ofthe dental prosthetic assembly 100 shown in FIGS. 1 through 3. Thedental prosthetic assembly 100 includes a reinforcement bar 102 with apolymer and glass-based outer layer 104 on the reinforcement bar 102.

The reinforcement bar 102 is formed from a lightweight material havingsignificant strength. The reinforcement bar 102 may be lighter thanother materials currently used in dental prosthetics (e.g., dentures).For example, the reinforcement bar 102 may be lighter than (e.g., have alower density than) titanium or solid zirconia. The lighter weight ofthe reinforcement bar 102 can reduce the energy expended for chewing orspeaking, thereby reducing the fatigue experienced by persons wearingthe dental prosthetic assembly 100 (relative to persons wearing otherdentures, such as dentures formed from solid zirconia).

In one embodiment, the reinforcement bar 102 is formed from acopolyester resin material having nanoceramic particles dispersedthroughout the bar 102. The reinforcement bar 102 may be semi-flexibleto absorb at least some of the mechanical shock that occurs during useof the dental prosthetic assembly 100 (e.g., during chewing). Forexample, the reinforcement bar 102 may be sufficiently strong to avoidsignificantly deformation (e.g., when a patient is chewing), but may beat least partially flexible such that the bar 102 can be partiallycompressed, move, or otherwise change shape by a greater amount relativeto a less flexible material, such as titanium, when the reinforcementbar 102 and the less flexible material are subjected to an equivalentforce. This can allow for the reinforcement bar 102 to absorb moremechanical shock caused by chewing or talking relative to othermaterials, such as titanium.

The reinforcement bar 102 may be more flexible than the outer layer 104.For example, when subjected to the same amount of force (e.g., a commonmagnitude of force, such as 250 pounds per square inch), thereinforcement bar 102 may change shape or absorb more force than theouter layer 104 and other materials, such as titanium and zirconia.

The outer layer 104 on the reinforcement bar 102 can be formed from amixture of polymer and glass. The polymer in the outer layer 104 can bea highly-filled resin material. The glass in the outer layer 104 can besilanated glass, or another type of glass. The outer layer 104 can beformed by mixing the polymer and glass in liquid form, and pressing thepolymer and glass at elevated temperatures and while under vacuum. Thiscan press the material of the outer layer 104 into a highly dense bodyhaving little to no porosity. Reducing or eliminating the porosity ofthe outer layer 104 can assist in reducing bacterial growth in thedental prosthetic assembly 100, which can occur in the more porousmaterials used in some known dentures (e.g., acrylic). For example, thevolume of pores or openings inside the outer layer 104 may be less(e.g., per unit volume) than the volume of pores or openings insideacrylic materials.

The outer layer 104 and the reinforcement bar 102 are chemically bondedto each other to increase the strength of the interface between theouter layer 104 and the reinforcement bar 102 relative to othermaterials (e.g., titanium and acrylic). In one embodiment, the outerlayer 104 and the reinforcement bar 102 are bonded together using a dualcure resin. This resin chemically lutes the outer layer 104 to thereinforcement bar 102 such that the outer layer 104 is held onto thereinforcement bar 102 by the attraction of atoms in the outer layer 104to atoms in the reinforcement bar 102 through sharing and/or exchangingelectrons. The dual cure resin can be cured by exposing the resin tolight for a limited period of time to initiate curing. The exposure ofthe resin to light can be terminated or otherwise end, and the resin cancontinue to cure on its own and without exposure to the curing light.

In one embodiment, the resin chemically bonds the outer layer 104 to thereinforcement bar 102 using covalent bonds between atoms of the outerlayer 104 and the reinforcement bar 102. In contrast, some known dentalprosthetics combine materials that are coupled by mechanical bonding,such as a connection formed by interlocked molecules of the materialswithout any chemical (e.g., covalent) bonds. The stronger chemical bondsbetween the outer layer 104 and the reinforcement bar 102 can reduce thelikelihood of or prevent the separation of the outer layer 104 from thereinforcement bar 102. This type of separation can occur with othercombinations of materials that do not coupled by chemical bonds, such astitanium and acrylic.

An exterior coating 106 is provided on the outer layer 104 to provide anatural look to the dental prosthetic assembly 100. This exteriorcoating 106 can be formed from a flowable composite polymer materialhaving a coloring to appear like tissue inside a mouth. As shown inFIGS. 4 through 7, the exterior coating 106 may not cover all of thebottom side (e.g., the teeth side) of the dental prosthetic assembly100. The outer layer 104 may be formed into the shape of teeth, such asby milling part of the material used to form the outer layer 104.

The dental prosthetic assembly 100 also includes a coupling system thatsecures the dental prosthetic assembly 100 to the mouth of a patient.Part of the coupling system is connected with the reinforcement bar 102and outer layer 104, while the remaining part of the coupling system isconnected with the mouth of the patient. FIGS. 1 through 7 illustratethe part of the coupling system connected with the reinforcement bar 102and the outer layer 104. This part of the coupling system includesplural elongated pins 108 that extend into lateral openings 110 (shownin FIG. 1) through the exterior coating 106 and the outer layer 104 intothe reinforcement bar 102. The lateral openings 110 are oriented alongdirections that is transverse to the direction in which the teeth formedby the outer layer 104 in the assembly 100 extend. For example, if theartificial teeth in the assembly 100 extend along vertical directions,then the lateral openings 110 are oriented along horizontal directionsthat are perpendicular to the vertical directions.

The reinforcement bar 102 includes several interior receptacles 112. Thereceptacles 112 are voids inside the reinforcement bar 102. Thereceptacles 112 accessible to the pins 108 through the lateral openings110. For example, the pins 108 may move toward and partially into thereceptacles 112 through corresponding lateral openings 110 along lateralinsertion directions 200 (shown in FIG. 2). The elongated pins 108 maymove away from and partially out of the receptacles 112 through thecorresponding lateral openings 110 along opposite lateral removaldirections 202 (shown in FIG. 2). Each of the pins 108 may be movedalong a corresponding insertion direction 200 in order to secure (e.g.,lock) the dental prosthetic assembly 100 into a mouth and may be movedalong a corresponding removal direction 202 in order to detach (e.g.,unlock) the dental prosthetic assembly 100 from the mouth. FIGS. 1, 2,4, and 5 show the pins 108 in unlocked or detached positions (alsoreferred to as an unlocked or detached state), where the pins 108 havebeen at least partially moved out of the receptacles 112. The top mosttwo pins 108 in FIG. 3 and the left most two pins 108 in FIG. 6 also arein the unlocked or detached positions. As described below, thisdisengages the pins 108 from complementary or matching holes in implantabutments or anchors affixed to the inside of a patient's mouth.

The bottom most two pins 108 in FIG. 3, the right most two pins 108 inFIG. 6, and the pins 108 in FIG. 7 are in locked or secured positions(also referred to as a locked or secured state), where the pins 108 havebeen at least partially moved into the receptacles 112. As describedbelow, this engages the pins 108 into complementary or matching holes inimplant anchors affixed to the inside of a patient's mouth to lock orsecure the dental prosthetic assembly 100 in the mouth.

FIGS. 8 and 9 illustrate implant anchors 800 of the coupling systemaccording to one embodiment. The implant anchors 800 are secured to bonebeneath a tissue surface 806 of the inside of a patient's mouth. Thisbone may be the maxilla (with the tissue surface 806 being the roof ofthe mouth) or the mandible (with the tissue surface 806 being theopposite side of the mouth).

The implant anchors 800 may be secured to the mouth using fasteners 802,such as screws. The implant anchors 800 include holes 804 shaped andsized to receive the pins 108 (shown in FIGS. 1 through 7) when the pins108 are in the locked or secured position or state. For example, thedental prosthetic assembly 100 (shown in FIGS. 1 through 7) can beplaced into a patient's mouth with the pins 108 retracted into theunlocked position.

The implant anchors 800 may be received into the recesses 112 (shown inFIGS. 1 through 3) of the reinforcement bar 102 (shown in FIGS. 1through 7). The pins 108 may then be actuated (e.g., laterally movedrelative to the direction in which the teeth extend in the mouth) in theinsertion directions 200 (shown in FIG. 2). This moves the pins 108 intoor through the holes 804 in the implant anchors 800. With the pins 108extending into or through these holes 804, the dental prostheticassembly 100 is secured to the patient's mount. For example, when theassembly 100 is coupled to the top side of a patient's mouth, theassembly 100 is prevented from being moved downward away from the roofof the patient's mouth by the pins 108 extending through the holes 804in the anchors 800. The assembly 100 may similarly be coupled to thebottom a patient's mouth using additional anchors 800 fixed to thepatient's mouth on the bottom of the inside of the patient's mouth. Toremove the dental prosthetic assembly 100 from the patient's mouth, thepins 108 are moved in the opposite retraction direction 202 (shown inFIG. 2). This moves the pins 108 out of the holes 108 in the implantanchors 800 so that the dental prosthetic assembly 100 can be removedfrom the patient's mouth.

FIG. 10 illustrates a flowchart of one embodiment of a method 1000 forproviding a dental prosthetic assembly. The method 1000 may be used tomanufacture the dental prosthetic assembly 100 shown in FIGS. 1 through7. At 1002, a reinforcement bar is obtained. The reinforcement bar maybe molded using a lightweight material having significant strength, suchas a copolyester resin material having nanoceramic particles dispersedthroughout. At 1004, a polymer-based outer layer is obtained. This layermay be a body formed from a mixture of polymer and glass, such as amixture of a highly filled resin material and silanated glass. Thepolymer-based outer layer may be molded into a shape that fits aroundthe reinforcement bar. Part of the polymer-based outer layer mayprotrude outward so that this part can be milled into the shape of teethof the dental prosthetic assembly.

At 1006, an adhesive is applied to the reinforcement bar and/orpolymer-based outer layer. For example, a dual cure resin may be appliedto the surface of the reinforcement bar that will face and/or engage thepolymer-based outer layer, and/or the resin may be applied to thesurface of the polymer-based outer layer that will face and/or engagethe reinforcement bar. At 1008, the reinforcement bar and thepolymer-based outer layer are chemically bonded together. The adhesivecan cure to chemically bond the reinforcement bar and the polymer-basedouter layer together. This prevents the polymer-based outer layer fromseparating from the reinforcement bar after continued use of the dentalprosthetic assembly.

At 1010, an exterior coating is applied to portions of the polymer-basedouter layer. This coating provides a natural look to the dentalprosthetic assembly, such as by having a color of tissue (e.g., a pinkcolor). This exterior coating can be formed from a flowable compositepolymer material having a coloring to appear like tissue inside a mouth.The coating may not be applied over the portions of the polymer-basedouter layer that will form the teeth of the dental prosthetic assembly.At 1012, the exposed portions of the polymer-based outer layer aremilled into the shapes of teeth. For example, the portions of thepolymer-based outer layer that were not covered by the exterior coatingmay be milled into the shape of teeth to complete assembly of the dentalprosthetic assembly.

In one embodiment, a dental prosthetic assembly includes a flexiblereinforcement bar and a polymer-based outer layer chemically bonded tothe reinforcement bar outside of the reinforcement bar. Thereinforcement bar forms an interior of the dental prosthetic assemblyand at least a portion of the outer layer forms teeth of the dentalprosthetic assembly.

The flexible reinforcement bar can have a density that is less thandensity of titanium or density of zirconia. The flexible reinforcementbar is more flexible than titanium when subjected to a common amount offorce in one example. Optionally, the flexible reinforcement bar isformed from a copolyester resin having nanoceramic particles in theresin. The flexible reinforcement bar can be more flexible than thepolymer-based outer layer when subjected to a common amount of force.

In one example, the polymer-based outer layer is formed from a glassfilled resin. Optionally, the polymer-based outer layer is formed from aresin having silanted glass in the resin. The polymer-based outer layercan be less porous than acrylic.

The assembly can also include a dual cure resin chemically bonding thereinforcement bar to the polymer-based outer layer. The assemblyoptionally can include a tissue-colored exterior coating on less than anentirety of an exterior surface of the polymer-based outer layer.

In one embodiment, a coupling system of a dental prosthetic assemblyincludes pins disposed in openings extending into the dental prostheticassembly and implant anchors configured to be coupled with a mouth of apatient. The implant anchors have holes configured to receive the pins.The pins secure the dental prosthetic assembly to the implant anchors bymoving into the dental prosthetic assembly through the openings and intothe holes of the implant anchors.

The openings in the dental prosthetic assembly can be laterally orientedwith respect to teeth of the dental prosthetic assembly, and the pinsare actuated in first lateral directions in the openings to secure thedental prosthetic assembly to the implant anchors. The pins can beactuated in opposite second lateral directions in the openings to detachthe dental prosthetic assembly from the implant anchors.

Optionally, the implant anchors are sized to fit into recesses in thedental prosthetic assembly. The openings in the dental prostheticassembly can laterally extend from outside of the dental prostheticassembly into the recesses in the dental prosthetic assembly.

In one embodiment, a method includes obtaining a flexible reinforcementbar, obtaining a polymer-based outer layer, chemically bonding thereinforcement bar with the polymer-based outer layer, and millingartificial teeth into the polymer-based outer layer to form a dentalprosthetic assembly. The reinforcement bar forms an interior of thedental prosthetic assembly.

In one example, the flexible reinforcement bar has a density that isless than density of titanium or density of zirconia. The flexiblereinforcement bar can be more flexible than titanium when subjected to acommon amount of force. The flexible reinforcement bar can be formedfrom a copolyester resin having nanoceramic particles in the resin.Optionally, the flexible reinforcement bar is more flexible than thepolymer-based outer layer when subjected to a common amount of force.

The polymer-based outer layer can be formed from a glass filled resin.In one example, the polymer-based outer layer is formed from a resinhaving silanted glass in the resin. The polymer-based outer layer can beless porous than acrylic.

Chemically bonding the reinforcement bar with the outer layer caninclude applying a dual cure resin to one or more of the reinforcementbar or the outer layer. The method may optionally also include applyinga tissue-colored exterior coating on less than an entirety of anexterior surface of the polymer-based outer layer.

The above description is illustrative and not restrictive. For example,the above-described embodiments (and/or aspects thereof) may be used incombination with each other. In addition, many modifications may be madeto adapt a particular situation or material to the teachings of theinventive subject matter without departing from its scope. While thedimensions and types of materials described herein are intended todefine the parameters of the inventive subject matter, they are by nomeans limiting and are example embodiments. Other embodiments may beapparent to one of ordinary skill in the art upon reviewing the abovedescription. The scope of the inventive subject matter should,therefore, be determined with reference to the appended claims, alongwith the full scope of equivalents to which such claims are entitled.

In the appended claims, the terms “including” and “in which” are used asthe plain-English equivalents of the respective terms “comprising” and“wherein.” Moreover, in the following claims, the terms “first,”“second,” and “third,” etc. are used merely as labels, and are notintended to impose numerical requirements on their objects. Further, thelimitations of the following claims are not written inmeans-plus-function format and are not intended to be interpreted basedon 35 U.S.C. § 112(f), unless and until such claim limitations expresslyuse the phrase “means for” followed by a statement of function void offurther structure. And, as used herein, an element or step recited inthe singular and proceeded with the word “a” or “an” should beunderstood as not excluding plural of said elements or steps, unlesssuch exclusion is explicitly stated. Furthermore, references to “oneembodiment” of the inventive subject matter are not intended to beinterpreted as excluding the existence of additional embodiments thatalso incorporate the recited features. Moreover, unless explicitlystated to the contrary, embodiments “comprising,” “including,” or“having” an element or a plurality of elements having a particularproperty may include additional such elements not having that property.

This written description uses examples to disclose several embodimentsof the inventive subject matter and also to enable a person of ordinaryskill in the art to practice the embodiments of the inventive subjectmatter, including making and using any devices or systems and performingany incorporated methods. The patentable scope of the inventive subjectmatter is defined by the claims, and may include other examples thatoccur to those of ordinary skill in the art. Such other examples areintended to be within the scope of the claims if they have structuralelements that do not differ from the literal language of the claims, orif they include equivalent structural elements with insubstantialdifferences from the literal languages of the claims.

What is claimed is:
 1. A dental prosthetic assembly comprising: asemi-flexible reinforcement bar; and a polymer-based outer layerchemically bonded to the semi-flexible reinforcement bar outside of thereinforcement bar, wherein the reinforcement bar forms an interior ofthe dental prosthetic assembly and at least a portion of thepolymer-based outer layer forms teeth of the dental prosthetic assembly.2. The dental prosthetic assembly of claim 1, wherein the polymer-basedouter layer is formed from a polymer and a glass.
 3. The dentalprosthetic assembly of claim 1, wherein the polymer-based outer layer iscure bonded to the semi-flexible reinforcement bar.
 4. The dentalprosthetic assembly of claim 1, wherein the polymer-based outer layer ismulti-cure bonded to the semi-flexible reinforcement bar.
 5. The dentalprosthetic assembly of claim 1, wherein the semi-flexible reinforcementbar includes ceramic particles.
 6. The dental prosthetic assembly ofclaim 1, wherein the semi-flexible reinforcement bar is more flexiblethan the polymer-based outer layer.
 7. The dental prosthetic assembly ofclaim 1, further comprising a cure resin that chemically bonds thereinforcement bar to the polymer-based outer layer.
 8. The dentalprosthetic assembly of claim 1, further comprising a colored exteriorcoating on less than an entirety of an exterior surface of thepolymer-based outer layer.
 9. A dental prosthetic assembly comprising: asemi-flexible reinforcement bar; and a glass-based outer layerchemically bonded to the semi-flexible reinforcement bar outside of thereinforcement bar, wherein the reinforcement bar forms an interior ofthe dental prosthetic assembly and at least a portion of the glass-basedouter layer forms teeth of the dental prosthetic assembly.
 10. Thedental prosthetic assembly of claim 9, wherein the glass-based outerlayer is formed from a polymer and a glass.
 11. The dental prostheticassembly of claim 9, wherein the glass-based outer layer is cure bondedto the semi-flexible reinforcement bar.
 12. The dental prostheticassembly of claim 9, wherein the glass-based outer layer is multi-curebonded to the semi-flexible reinforcement bar.
 13. The dental prostheticassembly of claim 9, wherein the semi-flexible reinforcement barincludes ceramic particles.
 14. The dental prosthetic assembly of claim9, wherein the semi-flexible reinforcement bar is more flexible than theglass-based outer layer.
 15. The dental prosthetic assembly of claim 9,further comprising a cure resin that chemically bonds the reinforcementbar to the glass-based outer layer.
 16. The dental prosthetic assemblyof claim 9, further comprising a colored exterior coating on less thanan entirety of an exterior surface of the glass-based outer layer.
 17. Amethod comprising: chemically bonding a semi-flexible reinforcement barwith a polymer-based outer layer; and forming an interior and teeth of adental prosthetic assembly using at least a portion of the polymer-basedouter layer.
 18. The method of claim 17, wherein chemically bonding thesemi-flexible reinforcement bar with the polymer-based outer layerincludes cure bonding the semi-flexible reinforcement bar with thepolymer-based outer layer.
 19. The method of claim 17, wherein thesemi-flexible reinforcement bar is chemically bonded to thepolymer-based outer layer using a cure resin.
 20. The method of claim17, further comprising milling one or more of the teeth in thepolymer-based outer layer.